X-ray intensifying screen containing hafnia phosphor

ABSTRACT

An intensifying screen for producing a latent image in a silver halide radiographic element when imagewise exposed to X-radiation is disclosed. The screen contains a phosphor having a hafnia host containing zirconia in concentrations higher than those found in optical grade hafnia. The phosphor can include as an activator one or a combination of titanium, rare earth, and alkali metal ions. Phosphor preparation processes are also disclosed.

FIELD OF THE INVENTION

The invention relates to novel X-ray intensifying screens. More specifically, the invention relates to fluorescent screens of the type used to absorb an image pattern of X-radiation and to emit a corresponding pattern of longer wavelength electromagnetic radiation. The invention additionally relates to certain novel phosphor compositions and to processes for their preparation.

BACKGROUND OF THE INVENTION

A developable latent image is formed in a silver halide emulsion layer of a radiographic element when it is imagewise exposed to X-radiation. Silver halide emulsions, however, more efficiently absorb and consequently are more responsive to longer (300 to 1500 nm) wavelength electromagnetic radiation than to X-radiation. Silver halide possesses native sensitivity to both the near ultraviolet and blue regions of the spectrum and can be sensitized readily to the green, red, and infrared portions of the electromagnetic spectrum.

Consequently it is an accepted practice to employ intensifying screens in combination with silver halide emulsion layers. An intensifying screen contains on a support a fluorescent phosphor layer that absorbs the X-radiation more efficiently than silver halide and emits to the adjacent silver halide emulsion layer longer wavelength electromagnetic radiation in an image pattern corresponding to that of the X-radiation received.

While the phosphor layer and emulsion layer can be integrated into one element, in most instances the adjacent silver halide emulsion layer is coated on a separate support to form a separate radiographic element. In this way, the intensifying screen, which is not permanently altered by exposure, can be reused. The most common arrangement for X-radiation exposure is to employ a dual coated radiographic element (an element with silver halide emulsion layers on opposite sides of a support), each emulsion layer being mounted adjacent a separate intensifying screen.

Phosphors employed in intensifying screens consist of a host compound, often combined with a small amount of another element that changes the hue and/or improves the efficiency of fluorescence. It is generally conceded that the reliable and reproducible creation of phosphors is among the most difficult of chemical investigations. H. W. Leverenz, An Introduction to Luminescence of Solids, John Wiley & Sons, Inc., New York, 1950, p. 61 states:

Synthesis and Symbolism of Phosphors

Efficient general research on phosphors requires (1) an exceptionally clean chemical laboratory equipped to synthesize very pure inorganic substances, (2) one or more furnaces capable of attaining at least 1600° C. with either oxidizing atmospheres, and (3) a physical laboratory having suitable sources of photons and charged material particles and means for controlling and determining the energies and numbers of these particles.

The chemical facilities are necessary to prepare luminescence-pure (LP) substances, who approximate degree of purity is indicated in the following series:

    ______________________________________                                         approx. 1%                                                                     . . . ore,                                                                     approx. 90%                                                                    technically pure,                                                              99.9%                                                                          chemically pure (CP),                                                          99.99%                                                                         reagent-grade pure (RP),                                                       99.999%                                                                        spectroscopically pure (SP),                                                   99.9999%                                                                       luminescence pure (LP),                                                        100%                                                                           . . . completely pure.                                                         ______________________________________                                    

Leverenz at page 62 and subsequently in his text goes on to suggest that research should be conducted with luminescence pure (LP) materials to reduce discrepancies in results. Leverenz is offered as an example of the general practice in the phosphor art of employing materials of much lower permissible levels of impurities than in many other fields of chemistry, ideally impurity levels at or below that of LP materials.

It has been recognized that the phosphors of highest absorption efficiencies are those in which the host compound contains at least one element from Period 6 of the Periodic Table of Elements. For example, barium sulfate, lanthanide oxyhalides and oxysulfides, yttrium tantalate, and calcium tungstate, are widely employed phosphor host compounds.

One family of phosphor host compounds that have shown promise in terms of performance, but have been little used are rare earth hafnates. L. H. Brixner, "Structural and Luminescent Properties of the Ln₂ Hf₂ O₇ -type Rare Earth Hafnates", Mat. Res. Bull., Vol. 19, pp. 143-149, 1984, describes investigations of such phosphor host compounds. Ln is defined to include not only lanthanides, but also scandium and yttrium. A significant practical disadvantage in formulating these host phosphor compounds is that firing to temperatures in the 1800° to 1900° C. range is required to obtain a single phase composition. These firing temperatures render rare earth hafnates burdensome to prepare as phosphor host compounds.

One hafnium containing phosphor host compound that has been recognized to possess high efficiency in its absorption of X-radiation, but has enjoyed no practical use is optical grade hafnia. Kelsey U.S. Pat. No. 4,006,097, issued May 5, 1975, discloses to be useful in the absorption of X-radiation a phosphor satisfying the formula:

    HfO.sub.2 :Yb

with Yb being present in a concentration of 5×10⁻³ to 1×10⁻¹.

Brixner, cited above, after reporting the properties of Ti⁺⁴ as an activator for rare earth hafnates, stated:

We also looked at this same activator in pure HfO₂. Under 30 kVp Mo radiation x-ray excitation, this composition also emits in a broad band centered around 477 nm as seen in FIG. 5. This emission has an intensity of about 1.6 times that of PAR CaWO₄ and could therefore be of interest as an x-ray intensifying screen phosphor, especially in light of the superior absorption of HfO relative to CaWO as seen in FIG. 6. Unfortunately, the price of optical grade HfO is so prohibitive that it cannot be used in screen applications. (Emphasis added.)

Optical grade hafnia contains less than 3×10⁻⁴ mole of zirconia per mole of hafnia. It is the difficulty in separating zirconium and hafnium that primarily accounts for the cost of optical grade hafnia.

Zirconium and hafnium are known to be atoms of essentially similar radii, 1.454 Å and 1.442 Å, respectively. Practically all known compounds of zirconium and hafnium correspond to the +4 oxidation state. The chemical properties of the two elements are essentially identical. The elements are found together in nature and can not be entirely separated.

Zirconia and hafnia both exist predominantly in a stable monoclinic crystalline phase at room temperature, with the size of the crystal cell being very similar. As reported by by E. Iwase and S. Nishiyama, "Luminescence Spectra of Trivalent Rare Earth Ions", Proc. Intern. Sym. Mol. Struct. Spectry., Tokyo, 1962, A-407-1 to 7, the crystal lattice constants of monoclinic hafnia and zirconia are as follows:

                  TABLE I                                                          ______________________________________                                         Oxide    a-axis  b-axis      c-axis                                                                               β                                      ______________________________________                                         HfO.sub.2                                                                               5.11    5.14        5.28  99° 44'                              ZrO.sub.2                                                                               5.21    5.26        5.375 99° 55'                              ______________________________________                                    

Iwase and Nishiyama investigated "high purity Hf and Zr compounds" for cathodoluminescence--i.e., fluorescence response to electron bombardment.

D. K. Smith and H. W. Newkirk, "The Crystal Structure of Baddeleyite (Monoclinic ZrO₂) and its Relation to the Polymorphism of ZrO₂ ", Acta Cryst., 18, 1965, pp. 983-991, demonstrates that large single crystals of monoclinic zirconia can be produced by heating ZrO₂ with a flux of Li₂ Mo₂ O₇ in an oven at 1400° C. and withdrawing the sample when it reaches 900° C.

Chenot et al U.S. Pat. Nos. 4,068,128 and 4,112,194 disclose a variety of phosphors formed of varied ratios of phosphorus, hafnium, oxygen, and, optionally, zirconium. The various phosphor hosts produced by phosphorus in combination with hafnium are, of course, crystallographically dissimilar from hafnia host phosphors and offer no reliable indication of the effect of zirconium on the luminescence of monoclinic hafnia crystals.

RELATED PATENT APPLICATION

Bryan et al U.S. Ser. No. 305,310, filed concurrently herewith and commonly assigned, titled PHOSPHOR COMPOSITION AND X-RAY INTENSIFYING SCREEN, now abandoned in favor of U.S. Ser. No. 393,602, filed Aug. 14, 1989, discloses the preparation of lithium hafnate phosphors containing higher levels of zirconium than are present in optical grade hafnium sources. In the preparation of the lithium hafnate phosphor hafnia has been also formed as a secondary phase.

SUMMARY OF THE INVENTION

In one aspect, the invention is directed to an intensifying screen comprised of a support and a fluorescent layer containing a phosphor capable of absorbing X-radiation and emitting longer wavelength electromagnetic radiation comprised of monoclinic crystals of a hafnia phosphor host. The intensifying screen is characterized in that zirconium ions are present in the hafnia phosphor host in concentrations higher than those found in optical grade hafnia.

In another aspect, the invention is directed to a composition containing a phosphor capable of absorbing X-radiation and emitting longer wavelength electromagnetic radiation which is comprised of monoclinic crystals of a hafnia phosphor consisting essentially of oxygen host and hafnium, zirconium, and alkali metal ions satisfying the relationship

    Hf.sub.1-z Zr.sub.z M.sub.y

wherein

M represents at least one alkali metal;

y is in the range of from 6×10⁻⁴ to 1.0; and

z is in the range of from 4×10⁻⁴ to 0.3.

In an additional aspect, the invention is directed to a process of preparing a phosphor capable of absorbing X-radiation and emitting longer wavelength electromagnetic radiation comprised of activated monoclinic crystals of a hafnia phosphor host by heating a hafnium containing compound and an activator containing compound to a temperature sufficient to form and activate the hafnia phosphor host. The process is characterized in that a phosphor exhibiting improved emission properties is obtained by forming a mixture of hafnium, zirconium, and alkali metal compounds containing thermally decomposable ligands chosen to leave residues consisting essentially of hafnium, zirconium, and alkali metal oxides on heating, the hafnium, zirconium, and alkali metal ions present prior to heating satisfying the relationship:

    Hf.sub.1-z Zr.sub.z M.sub.m

wherein

M represents at least one alkali metal;

m is greater than 5×10⁻² ; and

z is in the range of from 4×10⁻⁴ to 0.3.

DESCRIPTION OF PREFERRED EMBODIMENTS

An essential and novel feature of the intensifying screens of this invention is a hafnia host phosphor which contains higher levels of zirconium than is present in optical grade hafnia. As employed herein the term "optical grade hafnia" refers to hafnia sold as optical grade or prepared from any optical grade hafnium source.

Optical grade hafnia is the purest form of hafnia commercially available and is therefore sometimes referred to in the literature as "pure hafnia" and in the phosphor art, where high levels of purity are the normal practice, simply as hafnia. Optical grade hafnia contains less than 3×10⁻⁴ mole of zirconia per mole of hafnia.

The preferred phosphor host in the intensifying screens of this invention consists essentially of hafnia and zirconia with the hafnium and zirconium ions in the phosphor host satisfying the relationship

    Hf.sub.1-z Zr.sub.z                                        (I)

where z is in the range of from 4×10⁻⁴ to 0.3, most preferably from 1×10⁻³ to 0.2, and optimally from 2×10⁻³ to 0.1.

Stated another way, the present invention contemplates intensifying screens in which the phosphor host is prepared from reagent grade hafnia, which, referring to relationship I, is commercially available with z being slightly less than 2×10⁻². Surprisingly, this material forms a phosphor having a higher level of luminescence than optical grade hafnia. From the Examples below it is apparent that by blending reagent grade hafnium sources with optical grade hafnium sources so that z is about 1×10⁻² peak phosphor luminescence intensities are realized. The Examples below also demonstrate that by blending optical or reagent grade zirconium compounds with reagent grade hafnium compounds to form zirconium rich hafnia host phosphors, higher luminescence intensities than demonstrated by optical grade hafnia are also realized, until z reaches a level greater than 0.3. The fact that zirconia exhibits a lower luminescence intensity than hafnia when exposed to X-radiation is, of course, to be expected, since zirconium lies in Period 5 of the Periodic Table of Elements. That a limited range of zirconium concentrations in a hafnia host can increase phosphor luminescence has not been realized prior to this invention.

The small amounts of other elements found in commercially available reagent grade hafnium and zirconium source compounds are not detrimental to intensifying screen performance. Therefore, other possible impurities of the phosphor host need be given no further consideration.

In the simplest form of the invention monoclinic reagent grade hafnia can be purchased and formed into an intensifying screen. It is also possible to purchase reagent grade hafnium compounds corresponding to the optical grade hafnium compounds employed by Kelsey and Brixner, cited above, and to prepare phosphors according to the invention by those conventional procedures.

To form monoclinic phosphor particles containing a selected ratio of hafnium and zirconium, commercially available sources of zirconium and hafnium are intimately intermixed, preferably by being dissolved in a common solvent, followed by coprecipitation. The hafnium and zirconium containing mixture is chosen so that upon firing only hafnium, zirconium, and oxygen atoms remain as residue, any other moieties of the compounds being thermally decomposed or otherwise driven off in firing.

Common sources of hafnium and zirconium include the dioxides, the basic carbonates, the oxychlorides, the oxynitrates, the sulfates, and the tetrachlorides. While the dioxides, the basic carbonates, and the sulfates can be used as purchased to produce phosphors, it is advantageous for both handling and phosphor performance to convert the other sources to less soluble solids that can be fired to give the monoclinic Hf_(1-z) Zr_(z) O₂ phosphor desired. For example, treatment of aqueous hafnium and zirconium ion containing solutions with base (e.g., alkali or ammonium hydroxide) gives a precipitate which is a mixture of hydrous hafnia and hydrous zirconia, the relative proportions of which depend upon those present in the starting materials.

Other useful solids satisfying Hf_(1-z) Zr_(z) requirements can be produced by treating hafnium and zirconium ion containing solutions with organic precipitating agents, since organic materials consisting of carbon, hydrogen, and optionally nitrogen and/or oxygen leave no objectionable residue upon thermal decomposition.

Hafnium and zirconium can be conveniently coprecipitated as carboxylates, such as those containing from about 2 to 20 carbon atoms. The carboxylate moieties are in one preferred form aliphatic carboxylates containing from about 2 to 10 carbon atoms, including both monocarboxylates and polycarboxylates--particularly dicarboxylates, such as oxalates, succinates, fumarates, etc. Aromatic carboxylates, such as benzoates, phthalates, and their ring substituted homologues, are also convenient to use. A particularly preferred class of carboxylates are α-hydroxycarboxylates containing from 2 to 10 carbon atoms, such as glycolates, lactates, and mandelates. Oxalic acid can be viewed as either a dicarboxylic acid or an α-hydroxycarboxylic acid. Oxalates are particularly preferred moieties for forming not only hafnium and zirconium compounds, but also compounds of other metals to be incorporated in forming preferred forms of the phosphor more particularly described below. The carboxylate moieties can form simple carboxylates with the hafnium or zironium or can form hafnium or zirconium carboxylate complexes including additional cations, such as alkali metal or ammonium ions.

The hafnium and zirconium carboxylates can be conveniently formed by reacting in a common solvent the acid, salt, or ester of the carboxylate with hafnium and zirconium containing compounds in the ratios desired in the phosphor. The hafnium and zirconium containing compounds to be reacted can be selected from among compounds such as hafnium tetrachloride, zirconium tetrachloride, hafnium oxychloride, zirconium oxychloride, hafnium basic carbonate, zirconium basic carbonate, hafnium nitrate, zirconium nitrate, zirconium carbonate, hafnium sulfate, zirconium sulfate, and mixtures thereof.

It is also contemplated to employ hafnium and zirconium alkoxides as starting materials. Preferred hafnium and zirconium alkoxides are those which satisfy formula II:

    D(OR).sub.4                                                (II)

where

D represents zirconium or hafnium and

R represents a hydrocarbon moiety containing from about 1 to 20 (preferably about 1 to 10) carbon atoms. The hydrocarbon moieties can be chosen from any convenient straight or branched chain or cyclic saturated or unsaturated aliphatic hydrocarbon moiety--e.g., alkyl, cycloalkyl, alkenyl, or alkynyl. Alternatively the hydrocarbon moiety can be an aromatic moiety--e.g., benzyl, phenyl, tolyl, xylyl, naphthyl, etc. In a specifically preferred from R is in each instance lower alkyl of from 1 to 4 carbon atoms. Hafnium and zirconium alkoxides are disclosed in U.S. Pat. Nos. 3,297,414; 3,754,011; 4,525,468; and 4,670,472, the disclosures of which are here incorporated by reference.

In addition to alkoxide and carboxylate moiety containing hafnium and zirconium compounds various chelates, such as hafnium and zirconium β-diketones and diaminecarboxylates can be employed. Exemplary useful hafnium starting materials are set forth under heading III below. All the compounds have otherwise identical zirconium analogues. Further, although water of hydration has been omitted, it is to be understood that under normal ambient conditions most of the compounds exist as hydrates.

    ______________________________________                                         (III)                                                                          Exemplary Hafnium Starting Materials                                           ______________________________________                                         H-1      Hafnyl oxalate                                                                 HfO(C.sub.2 O.sub.4)                                                  H-2      Hafnyl oxalic acid                                                             H.sub.2 [HfO(C.sub.2 O.sub.4).sub.2 ]                                 H-3      Dioxalatohafnium                                                               Hf(C.sub.2 O.sub.4).sub.2                                             H-4      Trioxalatohafnic acid                                                          H.sub.2 [Hf(C.sub.2 O.sub.4).sub.3 ]                                  H-5      Ammonium trioxalatohafnate                                                     (NH.sub.4).sub.2 [Hf(C.sub.2 O.sub.4).sub.3 ]                         H-6      Potassium tetraoxalatohafnate                                                  K.sub.4 [Hf(C.sub.2 O.sub.4).sub.4 ]                                  H-7      Sodium tetraoxalatohafnate                                                     Na.sub.4 [Hf(C.sub.2 O.sub.4).sub.4 ]                                 H-8      Ammonium hafnyl oxalate                                                        (NH.sub.4).sub.2 [HfO(C.sub.2 O.sub.4).sub.2 ]                        H-9      Polyoxalatopolyhafnic acids                                           H-10     Potassium hafnyl tartrate                                                      K.sub.2 [HfO(C.sub.4 H.sub.4 O.sub.6).sub.2 ]                         H-11     Tetramandelatohafnic acid                                                      H.sub.4 [Hf(O.sub.2 CCHOC.sub.6 H.sub.5).sub.4 ]                      H-12     Triglycolatohafnic acid                                                        H.sub.3 HfOH(OCH.sub.2 COO).sub.3                                     H-13     Trilactohafnic acid                                                            H.sub.3 HfOH(OCHCH.sub.3 COO).sub.3                                   H-14     Trioxodihafnium stearate                                                       Hf.sub.2 O.sub.3 (O.sub.2 C(CH.sub.2).sub.16 CH.sub.3).sub. 2         H-15     Trioxodihafnium 2-ethylcaproate                                                Hf.sub.2 O.sub.3 (O.sub.2 CCHC.sub.2 H.sub.5 (CH.sub.2).sub.3                  CH.sub.3).sub.2                                                       H-16     Hafnium acetylacetonate                                                        Hf(C.sub.5 H.sub.7 O.sub.2).sub.4                                     H-17     Potassium bisnitrilotriacetohafnate                                            K.sub.2 {Hf[N(CH.sub.2 CO.sub.2).sub.3 ]}                             H-18     Hafnium ethylenediaminetetraacetic acid                                        Hf[(O.sub.2 CCH.sub.2).sub.2 NCH.sub.2 ].sub.2                        H-19     Hafnyl malonate                                                                HfO(O.sub.2 CCH.sub.2 CO.sub.2)                                       H-20     Hafnyl phthalate                                                               HfO(O.sub.2 C.sub.6 H.sub.4 CO.sub.2)                                 H-21     Hafnium tetraisopropoxide                                                      Hf(OC.sub.3 H.sub.7).sub.4                                            H-22     Hafnium tetra- .sub.-t-amyloxide                                               Hf(OC.sub.5 H.sub.11).sub.4                                           H-23     Hafnium tetra(phenoxide)                                                       Hf(OC.sub.6 H.sub.5).sub.4                                            H-24     Hafnium di(isopropoxide) bis(2-ethoxyethoxide)                                 Hf(OC.sub.3 H.sub.7).sub.2 (OC.sub.2 H.sub.4 OC.sub.2 H.sub.5).su              b.2                                                                   H-25     Hafnium tetra(cyclohexoxide)                                                   Hf(OC.sub.6 H.sub.11).sub.4                                           H-26     Hafnium di(isopropoxide) bis[2-(2-n-dodecan-                                   oxyethoxy)ethoxide]                                                            Hf(OC.sub.3 H.sub.7).sub.2 (OC.sub.2 H.sub.4 OC.sub.2 H.sub.4                  OC.sub.12 H.sub.25).sub.2                                             ______________________________________                                    

Formation of the zirconium rich monoclinic hafnia phosphor host is achieved by heating the zirconium and hafnium compounds to temperatures up to and including 1400° C. Higher firing temperatures can, of course, be undertaken, since the phosphor possesses high thermal stability. However, it is a distinct advantage of this invention that firing temperatures above 1400° C. are not required. Preferred firing temperatures are in the range of from about 900° to 1300° C.

Firing is continued until conversion to the monoclinic phase is achieved. For maximum firing temperatures the duration of firing can be less than 1 hour. While extended firing times are possible, once the phosphor has been converted to the monoclinic crystalline form, extending the duration of firing serves no useful purpose. Generally firing times in the range of from 1 to 10 hours, more typically 2 to 5 hours, provide full conversions of the starting materials to the phosphor composition sought.

Since the starting materials are in most instances decomposed at temperatures well below the 900° C. minimum temperature level contemplated for monoclinic crystal growth, it is generally convenient to heat the starting materials to a temperature above their decomposition temperature, but below 900° C., for an initial period to purge volatilizable materials before progressing to the higher crystallization temperatures. Typically, a preliminary heating step in the range of from about 300° to 900° C., preferably in the range of from 400° to 700° C., is undertaken.

It is also often convenient to divide firing into two or more consecutive steps with intermediate cooling to permit grinding and/or washing the material. Intermediate grinding can facilitate uniformity while intermediate washing, typically with distilled water, reduces the risk of unwanted contaminants, such as starting material decomposition by-products.

It has been discovered that firing the hafnia phosphor in the presence of a flux of one or a combination of akali metal ions incorporates alkali metal ion in the phosphor and dramatically increases its luminescence intensity. A preferred class of phosphors according to the present invention are those that satisfy the relationship:

    Hf.sub.1-z Zr.sub.z M.sub.y                                (IV)

where

M represents at least one alkali metal;

y is in the range of from 1×10⁻⁴ to 1 (preferably 0.2); and

z is as defined above.

Investigations have revealed that the benefits of alkali metal ion inclusion are fully realized at relatively low concentrations and incorporation of alkali metal ions in concentrations above those required for maximum luminescence enhancement are not detrimental to luminescence. There is no phosphor performance basis for limiting y to values of 1 or less. Rather it is primarily a phosphor preparation convenience.

Alkali metal ion inclusion in the phosphor can be conveniently accomplished by forming a mixture of the hafnium and zirconium starting materials discussed above and a compound capable of releasing alkali metal ions on heating. The amount of the alkali metal compound employed is chosen to supply alkali metal ion in a concentration in excess of that sought to be incorporated in the phosphor. Thus, the following is contemplated as a starting material relationship:

    Hf.sub.1-z Zr.sub.z M.sub.m                                (V)

wherein

M represents at least one alkali metal;

m is greater than 3×10⁻² (preferably from 1×10⁻¹ to 6); and

z satisfies any of the values noted in connection with relationships I and II.

The alkali metal compounds can be alkali metal analogues of the hafnium and zirconium starting materials discussed above. Preferred alkali metal compound starting materials include alkali metal carbonates, sulfates, oxalates, halides, hydroxides, borates, tungstates, and molybdates. Mixtures of alkali metal starting materials are contemplated, particularly when different alkali metals are being concurrently incorporated in the phosphor. Since in one form the hafnium and zirconium complexes of formula II can contain alkali metal ion, the alkali metal can wholly or in part be provided by these complexes. A convenient preparation approach is to employ alkali metal containing hafnium and zirconium complexes satisfying formula II and to increase the alkali metal content of the starting materials by adding other alkali metal compounds, as indicated above.

In relationship V, m can range of up to 10 or more. Most of the excess of alkali metal is removed during phosphor preparation. When an excess of alkali metal is incorporated in the phosphor, it is preferred to divide firing into two or more sequential steps with intermediate grinding and washing to remove soluble alkali metal compounds. This reduces the level of alkali metal compounds available for release during heating in a corrosive volatilized form and also reduces the possibility of forming less desirable secondary phases.

Investigation of alkali metal containing zirconium rich hafnia phosphors indicates that they exhibit increased levels of luminescence even after extended washing has reduced the alkali metal content to very low levels, approaching detection limits. While it is believed that the alkali metal is incorporated into the monoclinic crystals of the phosphor, this has not been conclusively established. It is possible that the alkali metal content of the phosphor is at least partially a surface remnant of the alkali metal flux on the surface of the monoclinic crystals during their formation during firing.

The highest levels of phosphor luminescence have been obtained by employing lithium as an alkali metal. In a preferred form lithium containing phosphors according to this invention satisfy the relationship:

    Hf.sub.1-z Zr.sub.z Li.sub.y                               (VI)

wherein

y is in the range of from 8×10⁻⁴ to 0.15 and

z is selected from any one of the ranges indicated above.

Lithium containing phosphors according to this invention are preferably prepared by selecting starting materials so that the hafnium, zirconium, and lithium ions present prior to heating satisfy the following relationship:

    Hf.sub.1-z Zr.sub.z Li.sub.m                               (VII)

wherein

m is in the range of from 4×10⁻² to 2.0 (optimally from 7×10⁻² to 1.5) and

z is selected as described above.

When lithium is selected as the alkali metal, it has been observed that, in addition to forming the zirconium rich hafnia phosphor with lithium included, a second phase of lithium hafnate can be formed, depending upon the proportion and selection of lithium compound starting materials. Since lithium hafnate lacks the luminescence intensities of titanium and lithium containing hafnia, a preferred embodiment of the invention, lithium starting materials and their concentrations are selected so that any overall luminescence of the two phases remains higher than that attained in the absence of lithium. As demonstrated in the Examples, increasing levels of lithium carbonate employed as a starting material results first in an increase in overall luminescence eventually followed by a decrease in overall luminescence attributed to the formation of increasingly larger proportions of lithium hafnate. On the other hand, employing lithium sulfate as a starting material, increasing proportions result in peak luminescence with still higher proportions of lithium sulfate resulting in a relatively constant high level of luminescence, indicating that the proportion of lithium hafnate which is formed as a second phase is limited at higher lithium sulfate concentrations in the starting materials.

Sodium and potassium compounds employed as starting materials in place of lithium compounds also result in markedly increased levels of phosphor luminescence. These alkali metal starting materials, of course, avoid any possibility of forming a lithium hafnate second phase and can therefore be employed well above the preferred maximum concentration levels of lithium starting materials without any performance penalty. On the other hand, it has been observed that sodium and potassium ions are quite effective at lower concentrations. Therefore, when M in relationship IV represents at least one of sodium and potassium, y is preferably in the range of from 6×10⁻⁴ to 7×10⁻² (optimally from 8×10⁻⁴ to 7×10⁻²).

The alkali metals cesium and rubidium are also effective to increase phosphor luminescence, but to a lesser extent that than lithium, sodium, and potassium. Combinations of any and all of the alkali metals can be employed in preparing the phosphors of this invention. Particularly useful are combinations of at least two of lithium, sodium, and potassium ions. Lithium and potassium ion combinations have produced particularly high levels of luminescence.

It is generally preferred to increase the fluorescence efficiency of the phosphor by blending with the phosphor host before firing a small amount of an activator. Any known activator for optically pure hafnia phosphors can be employed. Titanium (e.g., Ti⁺⁴), taught for use in optical grade hafnia by Brixner, cited above, is specifically contemplated for use as an activator. In one preferred form of the invention titanium is incorporated in the phosphor as an activator. Thus, in one preferred form of the phosphor hafnium, zirconium, and titanium are present and satisfy the relationship

    Hf.sub.1-z Zr.sub.z Ti.sub.x                               (VIII)

where

x is the range of from 3×10⁻⁴ to 1.0 (preferably 0.5 and optimally 0.25) and

z satisfies any of the ranges previously indicated.

It is possible to introduce the titanium activator by physically mixing titania with any of the host phosphor forming materials described above. It has been discovered, however, that higher luminescence levels at lower titanium concentrations are possible when the titanium activator in the form of a thermally decomposable compound is physically blended with thermally decomposable hafnium and zirconium compounds. The thermally decomposable moieties of the titanium activator compounds can be selected from among the same compound classes described in connection with hafnium and zirconium. Titanium carboxylates, where the carboxylates are chosen as described above, are particularly preferred starting materials for the incorporation of titanium.

The inclusion of titanium in the zirconium rich hafnia host phosphor not only greatly increases the total luminescence of the phosphor, but also shifts the maximum emission wavelength of the phosphor from the ultraviolet to the blue portion of the spectrum. Emissions in the blue portion of the spectrum are more useful for intensifying screen use, since the silver halide emulsions of radiographic elements which are employed in combination with intensifying screens possess native blue sensitivity and/or can be readily spectrally sensitized to these wavelengths while the organic vehicle of the emulsion is transparent in the blue portion of the spectrum.

In a specifically preferred form of the invention the zirconium rich hafnia phosphors include both alkali metal ion and titanium, each introduced as described above. In this form the phosphor satisfies the relationship:

    Hf.sub.1-z Zr.sub.z M.sub.y Ti.sub.x                       (IX)

where x, y, and z are as previously defined.

In a preferred form

x is in the range of from 3×10⁻⁴ to 1.0 (optimally 0.5);

y is in the range of from 6×10⁻⁴ to 1.0 (optimally 8×10⁻⁴ to 0.2); and

z is in the range of from 4×10⁻⁴ to 0.3 (optimally 1×10⁻³ to 0.2).

It has been surprisingly discovered that disproportionately large enhancements of luminescence are realized when both alkali metal ion and titanium are incorporated in the phosphor. That is, the luminescence increases imparted by each of the alkali metal ion and titanium alone when added together do not equal or even approach the magnitude of the luminescence increase imparted by a combination of alkali metal ion and titanium employed together in the phosphor.

Rare earth activators for the phosphors of this invention are also contemplated. As applied to this invention the term "rare earth" is intended to include scandium, yttrium, and the lanthanides. The following rare earths, taught by Iwase and Nishiyama, cited above, for use in high purity hafnia are also contemplated: praseodymium (e.g., Pr⁺³), samarium (e.g., Sm⁺³), europium (e.g., Eu⁺³), terbium (e.g., Tb⁺³), and dysprosium (e.g., Dy⁺³). Ytterbium, suggested by Kelsey, cited above, can also be employed as an activator. Gadolinium (e.g., Gd⁺³) is also shown to be an activator in the Examples below. Rare earth activators can enhance the intensity of phosphor luminescence, as demonstrated in the Examples below, and can be employed to shift the emission spectra of the phosphors of the invention.

Rare earth activated zirconium rich hafnia phosphors according to this invention preferably satisfy the relationship:

    Hf.sub.1-z Zr.sub.z L.sub.w                                (X)

or

    Hf.sub.1-z Zr.sub.z M.sub.y L.sub.w                        (XI)

wherein

L represents at least one rare earth element;

w is in the range of from 3×10⁻⁴ to <5×10⁻², preferably from 1×10⁻³ to 2×10⁻² ; and

y and z are as previously described.

As illustrated in the examples below, the zirconium can, as a function of its concentration, also permit fine tuning of the peak emission wavelength of the phosphor. Fine tuning to match the peak emission wavelength of the phosphor to the peak absorption wavelength of the silver halide emulsion layer to be exposed can have a significant impact on the efficiency of the overall imaging system. Thus, the zirconium a plays an important role not only in increasing the luminescence of the phosphor while reducing its cost, but also in optimizing its performance. By selection, specific combinations of zirconium concentrations and activator can produce phosphors with peak emission wavelengths that match dye absorption peaks in silver halide emulsion layers of radiographic elements.

The zirconium rich hafnia phosphors, once formed to satisfy the composition requirements of this invention, can be employed to form an intensifying screen of any otherwise conventional type. In its preferred construction the intensifying screen is comprised of a support onto which is coated a fluorescent layer containing the zirconium rich hafnia phosphor in particulate form and a binder for the phosphor particles. Zirconium rich hafnia phosphors can be used in the fluorescent layer in any conventional particle size range and distribution. It is generally appreciated that sharper images are realized with smaller mean particle sizes. Preferred mean particle sizes for the zirconium rich hafnia phosphors of this invention are in the range of from 0.5 μm to 40 μm, optimally from 1 μm to 20 μm.

It is, of course, recognized that the zirconium rich hafnia phosphor particles can be blended with other, conventional phosphor particles, if desired, to form an intensifying screen having optimum properties for a specific application. Intensifying screen constructions containing more than one phosphor containing layer are also possible, with the zirconium rich hafnia phosphor particles being present in one or more of the phosphor containing layers.

The fluorescent layer contains sufficient binder to give structural coherence to the zirconium rich hafnia layer. The binders employed in the fluorescent layers can be identical to those conventionally employed in fluorescent screens. Such binders are generally chosen from organic polymers which are transparent to X-radiation and emitted radiation, such as sodium o-sulfobenzaldehyde acetal of poly(vinyl alcohol); chlorosulfonated poly(ethylene); a mixture of macromolecular bisphenol poly(carbonates) and copolymers comprising bisphenol carbonates and poly(alkylene oxides); aqueous ethanol soluble nylons; poly(alkyl acrylates and methacrylates) and copolymers of alkyl acrylates and methacrylates with acrylic and methacrylic acid; poly(vinyl butyral); and poly(urethane) elastomers. These and other useful binders are disclosed in U.S. Pat. Nos. 2,502,529; 2,887,379; 3,617,285; 3,300,310; 3,300,311; and 3,743,833; and in Research Disclosure, Vol. 154, February 1977, Item 15444, and Vol. 182, June 1979. Particularly preferred intensifying screen binders are poly(urethanes), such as those commercially available under the trademark Estane from Goodrich Chemical Co., the trademark Permuthane from the Permuthane Division of ICI, Ltd., and the trademark Cargill from Cargill, Inc.

The support onto which the fluorescent layer is coated can be of any conventional type. Most commonly, the support is a film support. For highest levels of image sharpness the support is typically chosen to be black or transparent and mounted in a cassette for exposure with a black backing. For the highest attainable speeds a white support, such as a titania or barium sulfate loaded or coated support is employed. Specifically preferred reflective supports offering the highest attainable balance of speed and sharpness are those containing reflective microlenslets, disclosed by Roberts et al U.S. Ser. No. 243,374, filed Sept. 12, 1988, titled AN X-RAY INTENSIFYING SCREEN PERMITTING AN IMPROVED RELATIONSHIP OF IMAGING SPEED AND SHARPNESS, commonly assigned now U.S. Pat. No. 4,912,333.

Any one or combination of conventional intensifying screen features, such as overcoats, subbing layers, and the like, compatible with the features described above can, of course, be employed. Both conventional radiographic element and intensifying screen constructions are disclosed in Research Disclosure, Vol. 184, Aug. 1979, Item 18431, the disclosure of which and the patents cited therein are here incorporated by reference. Research Disclosure is published by Kenneth Mason Publications, Ltd., Emsworth, Hampshire P010 7DD, England.

In one specifically preferred form of the invention, illustrating intensifying screens satisfying the requirements of the invention intended to be employed with a separate silver halide emulsion layer containing radiographic element, the zirconium rich hafnia phosphor can be substituted for any of the conventional phosphors employed in either the front or back intensifying screens of Luckey, Roth et al U.S. Pat. No. 4,710,637, the disclosure of which is here incorporated by reference. Similar modification of any of the conventional intensifying screens disclosed in the following patents is also contemplated: DeBoer et al U.S. Pat. Nos. 4,637,898; Luckey, Cleare et al 4,259,588; and Luckey 4,032,471.

While the zirconium rich hafnia phosphors can be employed for their prompt emission following exposure to X-radiation, they can also be employed as storage phosphors--that is, for their ability to emit electromagnetic radiation in a chosen wavelength range after being exposed to X-radiation and then stimulated by exposure to radiation in a third spectral region. For example, the phosphors of this invention can be employed in imaging systems of the type disclosed by Luckey U.S. Pat. No. 3,859,527, the disclosure of which is here incorporated by reference. When employed in such a system the refractive indices of the phosphor and binder are preferably approximately matched, as disclosed by DeBoer et al U.S. Pat. No. 4,637,898, also incorporated by reference.

EXAMPLES

The invention can be better appreciated by reference to the following specific examples.

EXAMPLES 1-9 Phosphors Containing Varied Ratios of Hafnium and Zirconium (Hf_(1-z) Zr_(z))

The purpose of presenting these investigations is to demonstrate that, by varying the zirconium content in a hafnia host phosphor, enhanced phosphor luminescence intensity is achieved over a limited zirconium concentration range in which the zirconium content is higher than that found in optical grade hafnium sources, but still only a minor constituent.

Hafnia phosphor samples containing varied amounts of zirconium substituted for hafnium were prepared by the decomposition of the appropriate trilactohafnic and trilactozirconic acid complexes. The complexes were prepared by the general method described in W. B. Blumenthal, "The Chemical Behavior of Zirconium," VanNostrand, Princeton, N.J., 1958, p 333. The varying Hf:Zr ratios are obtained by using the appropriate mixtures of zirconium and hafnium oxychlorides in the precipitation reactions. The oxychlorides were obtained from Teledyne Wah Chang Albany (located at Albany, Oreg.) and used as received. The Hf:Zr ratios in the samples were determined from the analytical batch analyses provided by the supplier.

The preparation of trilactohafnic acid for Example 1 was carried out in the following manner: Optical grade (Hf_(1-z) Zr_(z), z=0.000276) hafnium oxychloride (40 g) and ACS reagent lactic acid (44 g) from Eastman Kodak Company were each dissolved in about 120 ml of distilled water. The hafnium oxychloride solution was added to the lactic acid solution with rapid stirring to form a precipitate, and the resulting mixture was heated to 80° C. with continued stirring for about 0.5 hours. The cooled mixture was filtered, and the collected solid was washed with distilled water. After drying for 15 hours at 80° C., the solid weighed 42 g. (for C₉ H₁₆ O₁₀ Hf: theory, C=23.4%, H=3.5%; found, C=22.7%, H=3.5%).

Approximately 13 g of the trilactohafnic acid was placed in a 50 mL alumina crucible, covered with an alumina lid, heated in air to 700° C. for one hour in an ashing furnace, then cooled to room temperature. The solid was transferred to a 20 mL alumina crucible, which was covered with an alumina lid. The covered 20 mL alumina crucible was placed into a 50 mL alumina crucible, which was thereafter covered with an alumina lid. The crucible assembly was heated to 1000° C. and maintained at that temperature for 2.5 hours before cooling to room temperature. The resulting solid was ground with an agate mortar and pestle to give a powder that was returned to the 20 mL alumina crucible. The 20 mL crucible was covered with its alumina lid and then heated to 1400° C. and maintained at that temperature for 1.5 hours before cooling to room temperature. The resulting solid was ground with an agate mortar and pestle to give a uniform phosphor powder.

The Example 1 phosphor powder sample was made from optical grade hafnium oxychloride and contained the lowest amount of zirconium. The Example 5 sample was made from reagent grade (designated by the supplier as Reactor Grade Special and subsequently also referred to as R.G.S.) hafnium (Hf_(1-z) Zr_(z), z=0.019) oxychloride. The Example 2, 3, 4A, and 4B samples were made by mixing appropriate amounts of the optical grade and reagent grade hafnium oxychlorides. The Example 6 to 9 samples were made by mixing appropriate amounts of reagent grade hafnium and zirconium oxychloride to obtain a zirconium content indicated in Table II.

The luminescence response of the phosphor powder was in this and all subsequent Examples measured by placing the phosphor powder sample in aluminum planchets (2 mm high×24 mm diam) at a coverage of about 1.1 g/cm² and exposing to X-radiation. The X-ray response was obtained using a tungsten target X-ray source in an XRD 6™ generator. The X-ray tube was operated at 70 kVp and 10 mA, and the X-radiation from the tube was filtered through 0.5 mm Cu and 1 mm Al filters before reaching the sample. The luminescent response was measured using an IP-28™ photomultiplier tube at 500 V bias. The voltage from the photomultiplier was measured with a Keithley™ high impedance electrometer and is proportional to the total light output of the sample.

The major luminescence peak of the phosphor samples was centered at about 280 nm. This value was obtained by taking the prompt emission spectrum of the powder using the unfiltered X-ray source described above. The tube was operated at 70 kVp and 30 mA. The spectrum was acquired with an Instruments S.A. Model HR 320™ grating spectrograph equipped with a Princeton Applied Research Model 1422/01™ intensified linear diode array detector. The data acquisition and processing was controlled by a Princeton Applied Research Model 1460 OMA III™ optical multichannel analyzer. The spectrum was corrected for the spectral response of the detector-spectrograph combination.

The relative luminescence intensity of the phosphor powder samples as a function of their zirconium content is set out in Table II.

                  TABLE II                                                         ______________________________________                                         Hf.sub.1-z Zr.sub.z                                                            EXAMPLE                                                                        NO.      Zr CONTENT (z) RELATIVE INTENSITY                                     ______________________________________                                         1 (Control)                                                                             0.000276       100                                                    2        0.00040        231                                                    3        0.0010         238                                                    4A       0.01           710                                                    4B       0.01           743                                                    5        0.019          365                                                    6        0.10           350                                                    7        0.20           155                                                    8        0.30           224                                                    9 (Control)                                                                             0.50            80                                                    ______________________________________                                    

The data of Table II demonstrate that there is an enhancement in hafnia phosphor performance when the zirconium level increased over that found in optical grade hafnium sources (represented by the Control 1). Ranges of z of from 4×10⁻⁴ (0.0004) to 0.3 are demonstrated to exhibit higher luminescence intensities than optical grade hafnia. Best results are demonstrated when z is in the range of from 1×10⁻³ (0.001) to 0.2, optimally in the range of from 5×10⁻³ (0.005) to 0.1.

EXAMPLES 10-14 Preparation of Phosphors in the Presence of an Alkali Metal Ion (Hf_(1-z) Zr_(z) M_(m))

The purpose of presenting these investigations is to demonstrate that the performance of hafnia host phosphors with an elevated zirconium level shown to be effective in Examples 1-9 can be further dramatically improved by preparing the hafnia phosphor in the presence of an alkali metal ion.

In each example a sample consisting of 14.72 grams of trilactohafnic acid (prepared as described in Examples 1-9 from RGS hafnium oxychloride, z=0.019) was thoroughly ground with an agate mortar and pestle with K₂ CO₃ or Li₂ CO₃ (Alfa Products; Ultra Pure grade). The mole percent of the alkali carbonate flux, based on hafnium, was chosen as indicated below in Table III. The mixtures prepared were heated as described above in Examples 1-9, except for the addition of a washing step after firing to 1000° C. This step involved washing the charge with 150 mL of distilled water for 1 hour. The solid was collected and dried for 5 minute intervals at 20, 35 and 50% power in a 500 W CEM model MDS-81™ microwave oven. The procedure described above in Examples 1-9 was then completed.

X-ray diffraction analysis of the samples confirmed the presence of monoclinic hafnia. The presence of alkali metal ion in the phosphor powder samples prepared in the presence of alkali carbonate flux was confirmed by atomic absorption analysis.

                  TABLE III                                                        ______________________________________                                         Hf.sub.1-z Zr.sub.z M.sub.m                                                    Example  M         m      Intensity (Ex. 1 = 100)                              ______________________________________                                          5       --        --     365                                                  10       K         0.2    520                                                  11       K         0.5    510                                                  12       K         2.0    545                                                  13       K         4.0    1005                                                 14       Li        0.14   1005                                                 ______________________________________                                    

A 140 to 275 percent increase in luminescence intensity relative to Example 5 is seen in the above examples containing alkali metal ion.

Referring back to Example 1, it is apparent that the hafnia phosphor samples containing both zirconium in higher levels than found in optical grade hafnium sources and alkali metal ion exhibit luminescence intensities ranging from >5 to >10 times those demonstrated by the hafnia phosphor prepared from an optical grade hafnium source.

EXAMPLES 15-18 Titanium Activated Phosphors (Hf_(1-z) Zr_(z) Ti_(x))

The purpose of presenting these investigations is to demonstrate the utility of titanium as an activator for the hafnia phosphors of this invention containing higher than optical grade concentrations of zirconia. The titanium also shifts the maximum spectral emission band of the phosphor to visible wavelengths in the blue portion of the spectrum.

In each example a sample consisting of 14.72 grams of trilactohafnic acid (prepared as described above in Examples 1-9, z=0.019) was thoroughly ground with varying portions of ammonium bis(oxalato)oxotitanium (IV), (NH₄)₂ TiO(C₂ O₄)₂ 2H₂ O, from Johnson Matthey (99.998%). The mole percent titanium, based on hafnium, is indicated below in Table IV. The mixtures were heated and further examined as in Examples 1-9.

X-ray diffraction analyses of Examples 17 and 18 each showed traces of unreacted TiO₂. A small amount of hafnium titanate was detected as an impurity phase in Example 18.

The relative luminescence outputs of Examples 5 and 15-18 are set out in Table IV. Not only were the luminescence outputs greatly increased in Examples 15-18, but the luminescence band maximum shifted to 475 nm, thereby providing increased emissions of visible spectrum wavelengths more advantageous for intensifying screen applications.

                  TABLE IV                                                         ______________________________________                                         Hf.sub.1-z Zr.sub.z Ti.sub.x                                                   Example      x      Intensity (Ex. 1 = 100)                                    ______________________________________                                          5           --      365                                                       15           0.02   5330                                                       16           0.05   4000                                                       17           0.10   2730                                                       18           0.25   1680                                                       ______________________________________                                    

From Table IV it is apparent that the inclusion of titanium in the hafnia phosphor samples containing higher than optical grade zirconium concentrations resulted in large increases in luminescence intensities. Thus, the titanium acted as an activator for the phosphor samples.

EXAMPLES 19-33 Preparation of Titanium Activated Phosphors in the Presence of Lithium Carbonate (Hf_(1-z) Zr_(z) Ti_(x) Li_(m))

The purpose of presenting these investigations is to demonstrate that the performance of hafnia host phosphors with an elevated zirconium level (z=0.19) and containing titanium as an activator can be further improved by preparing the hafnia phosphor in the presence of an alkali metal ion.

A sample consisting of 12.26 g of trilactohafnic acid (prepared as in Examples 1-9) was thoroughly ground with 0.1 g (5 mole percent, x=0.05) of TiO₂ (EM Chemicals; Optipur grade) and a selected amount of Li₂ CO₃ (Alfa Products; Ultrapure grade). The mixtures were processed and tested similarly as in Examples 10-14. In Examples 21-23 the size of the trilactohafnic acid sample was 13.00 grams with the titania increased to 0.106 g to maintain the titanium at 5 mole percent (x=0.05).

The relative intensity of the titanium activated phosphor samples as a function of the alkali metal flux employed is given in Table V.

                  TABLE V                                                          ______________________________________                                         Hf.sub.1-z Zr.sub.z Ti.sub.x M.sub.m                                           Example      m      Intensity (Ex. 1 = 100)                                    ______________________________________                                         19           0      2520                                                       20           0.01   2210                                                       21           0.02   1000                                                       22           0.06   3380                                                       23           0.10   6370                                                       24           0.10   5960                                                       25           0.20   13500                                                      26           0.20   14000                                                      27           0.40   13700                                                      28           0.50   13300                                                      29           0.50   13500                                                      30           1.0    8695                                                       31           1.5    5610                                                       32           2.0    3155                                                       33           4.0     735                                                       ______________________________________                                    

Samples in which more than 10 mole percent (m=0.20) Li₂ CO₃ was added revealed the presence of lithium hafnate in the X-ray powder patterns. The amount of lithium hafnate formed in the samples increased with the Li₂ CO₃ amount. At 200 mole percent (m=4.0) Li₂ CO₃ added, lithium hafnate is the primary phase.

From Table V it can be appreciated that values of m of from about 4×10⁻² (0.04) to 2.0 gave significantly improved results, with values of m of from about 1×10⁻¹ (0.10) to 1.5 providing the highest luminescence intensities observed in these comparisons.

In these comparisons it should be noted that Example 19 did not provide luminescence intensity as high as that reported in Table IV for Example 16, even though both contained 5 mole percent titanium (x=0.05) and neither was prepared in the presence of an alkali metal flux. This difference is attributed to the less efficient incorporation of the titanium activator in Example 19 resulting from employing titania rather than a titanium carboxylate salt as a starting material.

EXAMPLES 34-43 Preparation of Titanium Activated Phosphors in the Presence of Lithium Sulfate (Hf_(1-z) Zr_(z) Ti_(x) Li_(m))

The purpose of presenting these investigations is to demonstrate that the proportions of lithium hafnate formed as a second phase can be controlled and reduced by substituting another lithium salt for lithium carbonate.

The same procedures were employed as in Examples 19-33, except that for Li₂ CO₃ there was substituted Li₂ SO₄ (Aldrich anhydrous: 99.99%).

The relative intensity of the titanium activatived phosphor samples as a function of the lithium sulfate flux employed is given in Table VI. In Table VI the performance data from Table V is also represented for samples prepared using lithium carbonate at the concentration levels as the lithium sulfate.

                  TABLE VI                                                         ______________________________________                                         Hf.sub.1-z Zr.sub.z Ti.sub.x M.sub.m                                           Li.sub.2 CO.sub.3                                                                              Li.sub.2 SO.sub.4                                              Example                                                                               m       Intensity                                                                               Example  m    Intensity                                ______________________________________                                         20     0.01    2210     34       0.01 1545                                     21     0.02    1000     35       0.02 1545                                                             36       0.04 2105                                     22     0.06    3380     37       0.06 3605                                     23     0.10    6370     38       0.10 7645                                     24     0.10    5960                                                            25     0.20    13500    39       0.20 9115                                     26     0.20    14000                                                           28     0.50    13300    40       0.50 12400                                    30     1.0     8695     41       1.0  9820                                     32     2.0     3155     42       2.0  9330                                     33     4.0      735     43       4.0  9185                                     ______________________________________                                    

The most important advantage of employing lithium sulfate as a flux as compared to lithium carbonate is that a reduced amount of the lithium hafnate phase is produced. This results in significant improvements in phosphor luminescence when higher proportions of the lithium flux are employed during phosphor formation. At lower, preferred flux concentrations the lithium carbonate flux yields higher luminescence.

EXAMPLES 44-47 Preparation of Phosphors in the Presence of Varied Alkali Metal Ions

The purpose of presenting these investigations is to demonstrate that all of the alkali metals significantly enhance phosphor luminescence.

Example 25 was repeated, except that 10 mole percent (m=0.2) of another alkali metal carbonate was substituted for lithium carbonate: Na₂ CO₃ (0.265 g; EM Chemicals Suprapur Reagent), K₂ CO₃ (0.346 g; Alfa Products Ultrapure grade), Rb₂ CO₃ (0.5774 g; AESAR 99.9%), or Cs₂ CO₃ (0.8146 g; AESAR 99.9%).

The luminescence intensities measured for the resulting samples are set out in Table VII.

                  TABLE VII                                                        ______________________________________                                         Example  Carbonate source                                                                            Intensity (Ex. 1 = 100)                                  ______________________________________                                         19       None         2520                                                     25       Li.sub.2 CO.sub.3                                                                           13500                                                    44       Na.sub.2 CO.sub.3                                                                           10400                                                    45       K.sub.2 CO.sub.3                                                                            5400                                                     46       Rb.sub.2 CO.sub.3                                                                           3645                                                     47       Cs.sub.2 CO.sub.3                                                                           4840                                                     ______________________________________                                    

From Table VII it is apparent that all of the alkali metals are effective to increase the luminescence of the hafnia phosphors prepared from sources having higher zirconium contents than found in optical grade sources of hafnium. From Table VII it is observed that the lower the atomic number alkali metals lithium, sodium, and potassium offer a significant performance advantage over the heavier alkali metals rubidium and cesium when equal starting concentrations are employed.

EXAMPLES 48-51 Preparation of Phosphors Using Varied Alkali Metal Compounds

The purpose of presenting these investigations is to demonstrate the utility of alkali metal compounds completed by moieties other than sulfate and carbonate.

Example 25 was repeated, except that one of the following lithium sources was substituted for lithium carbonate: 0.2548 g Li₂ C₂ O₄ (10 mole percent, m=0.2, Alfa Products reagent grade), 0.212 g LiCl (20 mole percent, m=0.2, Alfa Products anhydrous Ultrapure grade), 0.4343 g LiBr (20 mole percent, m=0.2, MCB anhydrous) or 0.21 g LiOH--H₂ O (20 mole percent, m=0.2, MCB reagent).

The luminescence intensities are given in Table VIII.

                  TABLE VIII                                                       ______________________________________                                         Example   Lithium Cmpd.                                                                              Intensity (Ex. 1 = 100)                                  ______________________________________                                         19        None        2520                                                     48        Li.sub.2 C.sub.2 O.sub.4                                                                   12695                                                    49        LiCl        6730                                                     50        LiBr        9400                                                     51        LiOH:H.sub.2 O                                                                             13185                                                    ______________________________________                                    

From Table VIII it is apparent that all of the lithium compounds improve the luminescence of the phosphor. While both lithium hydroxide and lithium oxalate produced significantly higher levels of luminescence than the lithium halides, alkali carboxylates are clearly more convenient to handle than alkali hydroxides.

EXAMPLES 52-54 Enhancement of Phosphor Luminescence by a Combination of Titanium and Alkali Metal Ion

The purpose of presenting these investigations is to demonstrate the synergistic improvement of luminescence produced by the combination of an alkali metal ion and the titanium activator.

EXAMPLE 52

A sample consisting of 13.475 g of trilactohafnic acid (prepared as described in Examples 1-9) was thoroughly ground in an agate mortar and pestle with 0.2032 g Li₂ CO₃ (10 mole percent, m=0.2, Alfa Products Ultrapure grade) and processed as in Examples 10-14.

EXAMPLE 53

Example 15 was repeated, except that 13.475 g of trilactohafnic acid was used with 0.44 g of TiO₂ (2 mole percent, x=0.02, EM chemicals Optipur grade).

EXAMPLE 54

Example 53 was repeated, except for the addition of 0.2032 g Li₂ CO₃ (10 mole percent, m=0.2, Alfa Products Ultrapure grade) in the starting mixture.

The luminescence performances of Examples 5 and 52-54 are compared in Table IX.

                  TABLE IX                                                         ______________________________________                                         Example  Additions      Intensity (Ex. 1 = 100)                                ______________________________________                                          5       none            365                                                   52       10 mole % Li.sub.2 CO.sub.3                                                                   1120                                                   53        2 mole % TiO.sub.2                                                                           5690                                                   54       10 mole % Li.sub.2 CO.sub.3 +                                                                 14600                                                            2 mole % TiO.sub.2                                                   ______________________________________                                    

From Table IX it is apparent that a disproportionately large increase in luminescence was realized by employing both the titanium activator and the alkali metal ion. While each of the titanium and alkali metal alone enhanced luminescence, a larger increase in luminescence was attained when titanium and alkali metal ion were employed together than could have been predicted assuming the separate enhancements of luminescence to be fully additive.

EXAMPLES 55-62 Phosphors Containing 5 Mole Percent or Less Titanium

The purpose of presenting these investigations is to demonstrate the enhancements in luminescence produced by the use as starting materials of titanium at concentrations of 5 mole percent (x=0.05) and less, thereby presenting a better performance definition of the lower ranges of titanium concentrations.

Potassium tetraoxalatohafnate (IV) 5-hydrate was prepared as described in Inorg. Syn., VIII, 42 (1966) using R.G.S. hafnium oxychloride 8-hydrate (z=0.019). Upon drying at 70°-90° C. for 1-16 hours in a convection oven, the product analyzed at closer to a 3-hydrate composition and all subsequent use of this material was calculated as the 3-hydrate. Fifteen grams of the material was thoroughly ground in a agate mortar and pestle with 0.03-5 mole percent of potassium bis(oxalato)oxotitanate (IV) 2-hydrate (Alfa Products, recrystallized from ethanol). The mixtures were placed in 20 mL alumina crucibles, covered with alumina lids, and then placed in 100 mL alumina crucibles, which were covered with alumina lids. The samples were heated in air to 1000° C. for 2.5 hours, then cooled to room temperature. The resulting solids were removed from the crucibles, broken into small pieces with an alumina mortar and pestle and washed by stirring in 50 mL of distilled water. The solids were then collected and dried in a convection oven at 80° C. The charges were placed in 10 mL alumina crucibles with alumina lids and heated in air to 1300° C. for 2 hours, followed by cooling to room temperature.

The luminescence intensities of the samples are set out in Table X.

                  TABLE X                                                          ______________________________________                                         Example  Mole percent Ti                                                                             Intensity (Ex. 1 = 100)                                  ______________________________________                                          5       None          365                                                     55       0.03         5750                                                     56       0.3          6128                                                     57       1            9470                                                     58       2            10500                                                    59       3            8420                                                     60       3            9820                                                     61       4            8060                                                     62       5            9120                                                     ______________________________________                                    

From Table X it is apparent that even at the lowest concentrations of titanium (Hf_(1-z) Zr_(z) Ti_(x) where x=3×10⁻⁴, Example 55) much higher levels of luminescence are observed than in Example 5, which lacked titanium. While some of the enhancement in luminescence as compared to Example 5 can be attributed to the presence of potassium, comparing luminescence values from Table III, in which potassium was introduced without titanium being present, it is apparent that a part of the luminescence enhancement must be attributed to additional presence of the titanium.

EXAMPLES 63-68 Varied Levels of Zirconium in Phosphors Prepared in the Presence of Alkali Metal Ion

The purpose of presenting these investigations is to demonstrate the effect of varied levels of zirconium in the hafnia host phosphor when the hafnia phosphor was prepared in the presence of alkali metal ion.

Two grades of potassium tetraoxalatohafnate (IV) 3-hydrate were prepared as in Example 55 from optical grade hafnium oxychloride 8-hydrate and R.G.S. hafnium oxychloride 8-hydrate. Potassium tetraoxalatozirconate 3-hydrate was prepared as in Example 55 from R.G.S. zirconium oxychloride 8-hydrate. A series of Hf_(1-z) Zr_(z) O₂ samples in which z was varied from 2.76×10⁻⁴ to 6.84×10⁻² were prepared from mixtures of the above precursors. The powders were combined and ground in an agate mortar and pestle. The procedures of Examples 55-62 were employed, with the addition of 10 mole percent K₂ CO₃ (Alfa Products Ultrapure grade) to each sample.

Luminescence intensities as a function of zirconium levels (z) are given in Table XI.

                  TABLE XI                                                         ______________________________________                                         Example     z         Intensity (Ex. 1 = 100)                                  ______________________________________                                         63(Control) 2.8 × 10.sup.-4                                                                    380                                                      64          4.3 × 10.sup.-4                                                                    165                                                      65          9.6 × 10.sup.-3                                                                    770                                                      66          1.9 × 10.sup.-2                                                                    520                                                      67          4.0 × 10.sup.-2                                                                    595                                                      68          6.0 × 10.sup.-2                                                                    610                                                      ______________________________________                                    

Note that Example 66 was identical to Example 10, except for employing a different final firing temperature, and the luminescence measured was identical.

Table XI demonstrates that hafnia prepared from optical grade sources as in Control Example 63 yields inferior luminescence as compared to samples in which the zirconium content z is equal to at least 1×10⁻². Comparing Tables II and XI, it is apparent that the presence of potassium ion is responsible for a significant increase in luminescence at zirconium levels equal to that in R.G.S. hafnia (z=0.019) and above.

EXAMPLES 69-72 Determinations of Alkali Metal Ion Incorporation in Phosphors Differing in Zirconium Levels

The purpose of presenting these investigations is to provide quantitative determinations of alkali ion incorporation levels (y) in several phosphors satisfying the general relationship Hf_(1-z) Zr_(z) Ti_(x) M_(y) and having differing zirconium levels (z) satisfying the requirements of the invention.

Samples were prepared as in Examples 63-68, except for the further addition of 0.2151 g of recrystallized potassium bis(oxalato)oxotitanate (IV) 2-hydrate (Alfa Products) to satisfy the ratio x=0.03.

Proportions of zirconium, titanium, and potassium ion in the completed phosphor samples were determined by atomic absorption analysis and inductively coupled plasma spectrometry. The luminescence of the phosphors together with their alkali ion content observed on analysis, y(obs), are reported in Table XII. The amounts of zirconium and titanium present in the starting materials, z(calc) and x(calc), are compared in Table XII to the amounts of zirconium and titanium found on analysis, z(obs) and x(obs).

                  TABLE XII                                                        ______________________________________                                         Hf.sub.1-z Zr.sub.z Ti.sub.x M.sub.y                                                Intensity                                                                      (Ex.                                                                      Ex.  1 = 100) z(calc) z(obs)   x(calc)                                                                              x(obs)                                                                               y(obs)                              ______________________________________                                         69   9820     4.3 × 10.sup.-4                                                                  4.31 × 10.sup.-4                                                                  0.03  0.022 0.022                               70   9820     9.6 × 10.sup.-4                                                                  8.79 × 10.sup.-4                                                                  0.03  0.026 0.019                               71   9820     1.9 × 10.sup.-2                                                                  1.78 × 10.sup.-2                                                                  0.03  0.031 0.025                               72   9820     4.0 × 10.sup.-2                                                                  3.87 × 10.sup.-2                                                                  0.03  0.027 0.023                               ______________________________________                                    

Although all samples exhibited similar luminescence, when a corresponding phosphor was formed from optical grade hafnium starting materials [z(obs)=2.91×10⁻⁴ ], a significantly lower luminescence was observed.

EXAMPLE 73-77 Rare Earth Activated Phosphors

The purpose of presenting these investigations is to demonstrate enhanced performance of rare earth activatored zirconium rich hafnia phosphors--Hf_(1-z) Zr_(z) L_(w), where L represents a rare earth, z=0.019.

EXAMPLE 73

A sample consisting of 15.00 g of potassium tetraoxalatohafnate (IV) 3-hydrate prepared as in Example 55 was combined and ground thoroughly with 0.0861 g (x=0.03) of Eu(NO₃)₃.6H₂ O (Johnson Matthey REacton grade, 99.99%). The mixture was fired in a double alumina crucible setup (described in Example 1) to 1000° C. in air for 2 hours. The recovered ingot was broken into small chunks and washed in 70-150 mL of distilled water. The relative luminescence intensity was 770.

When Example 73 was repeated with increased levels of zirconium, small shifts in emission maxima were observed, indicating that zirconium content can be usefully varied in preparing these phosphors for use in intensifying screens. In intensifying screens intended to be employed with spectrally sensitized silver halide radiographic elements optimum imaging efficiency occurs when the emission peak of the phosphor corresponds with the absorption peak of the spectral sensitizing dye or dye combination present in the radiographic element.

EXAMPLE 74

A sample consisting of 14.82 g of potassium tetraoxalatohafnate (IV) 3-hydrate prepared from R.G.S. hafnium oxychloride 8-hydrate was ground with 0.0042 g (x=0.001) SmF₃ (Johnson Matthey REacton grade) and processed as in Example 73. The relative luminescence output was 735.

EXAMPLE 75

Example 74 was repeated, however, 0.083 g (x=0.02) of SmF₃ was used. The relative luminescence output was 400.

EXAMPLE 76

A sample consisting of 15.00 g of potassium tetraoxalotohafnate (IV) 3-hydrate prepared from R.G.S. hafnium oxychloride 8-hydrate was ground with 0.11 g (x=0.015) of Gd₂ O₃ (Rhone Poulenc 99.99%). The mixtures were fired as in Example 73, and then reheated in air at 1300° C. for 2.5 hours. The relative luminescence output was 430.

EXAMPLE 77

Example 76 was repeated, except that 0.22 g (x=0.03) of Gd₂ O₃ was used. The relative luminescence output was 490.

EXAMPLE 78 Intensifying Screen

The purpose of presenting these investigations is to demonstrate enhanced performance of intensifying screens containing zirconium rich hafnia phosphors.

Hafnyl oxalic acid 3-hydrate was prepared for use as a starting material in the manner described in Zhurnal Neoorganicheskoi Khimi, Vol. II, p. 980 (1957) using R.G.S. hafnium oxychloride, z=0.019. Two samples each consisting of 55.29 g of hafnyl oxalic acid 3-hydrate were thoroughly ground with 1.11 g of Li₂ CO₃ (Aldrich; reagent grade), 4.36 g of K₂ SO₄ (J. T. Baker; reagent grade) and 0.50 g of TiO₂ (EM Chemicals; Optipur grade).

The samples were placed in 250 mL alumina crucibles, covered with alumina lids, and heated in air to 1000° C. for 2.5 hours, then cooled to room temperature. The resulting solids were removed from the crucibles, broken into small pieces with a mortar and pestle, and washed by stirring in 500 mL of distilled water. Each sample was then collected and dried in a convection oven at 80° C. The charges were placed in 50 mL alumina crucibles with alumina lids and heated in air to 1400° C. for 1.5 hours, followed by cooling to room temperature. The two samples (combined weight, 53.1 g) were ground together and shaken through a nylon sieve with 60 μm openings to give 28.6 g of product phosphor.

The phosphor was mixed with 13% Permuthane™ polyurethane solution in a methylene chloride and methanol mixture to produce a dispersion with 25 parts of phosphor and 1 part of binder by weight. The dispersion was coated on a blue tinted transparent poly(ethylene terephthalate) film support to produce a coating with about 6.25 g/dm² of the phosphor. This coating when excited with unfiltered X-rays from a tungsten target tube operated at 70 kVp and 10 mA gives a speed that is about 3.5 times larger than that obtained from a commercial CaWO₄ (PAR screen) when the emission is compared using an IP-28™ photomultiplier tube.

The invention has been described in detail with particular reference to preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention. 

What is claimed is:
 1. An X-ray intensifying screen comprised ofa support and a fluorescent layer containing an organic binder that is transparent to X-radiation and to radiation emitted when the layer is excited by X-radiation and a phosphor capable of absorbing X-radiation and emitting longer wavelength electromagnetic radiation comprised of monoclinic crystals of a hafnium dioxide phosphor host consisting essentially of oxygen and combined elements satisfying the relationship

    Hf.sub.1-z Zr.sub.z

wherein z is in the range of from 4×10⁻⁴ to 0.3, said phosphor exhibiting a higher luminescence intensity when excited by X-radiation as compared to the phosphor as described above differing solely in that z is less than 4×10⁻⁴.
 2. An X-ray intensifying screen according to claim 1 in which z is in the range of from 1×10⁻³ to 0.2.
 3. An X-ray intensifying screen according to claim 2 in which z is in the range of from 2×10⁻³ to 0.1.
 4. An X-ray intensifying screen comprised ofa support and a fluorescent layer containing an organic binder that is transparent to X-radiation and to radiation emitted when the layer is excited by X-radiation and a phosphor capable of absorbing X-radiation and emitting longer wavelength electromagnetic radiation comprised of monoclinic crystals of a hafnium dioxide phosphor consisting essentially of oxygen and combined elements satisfying the relationship

    Hf.sub.1-z Zr.sub.z M.sub.y

whereinM represents ions of at least one alkali metal; y is in the range of from 1×10⁻⁴ to 1; and z is in the range of from 4×10⁻⁴ to 0.3, said phosphor exhibiting a higher luminescence intensity when excited by X-radiation as compared to the phosphor as described above absent M.
 5. An X-ray intensifying screen according to claim 4 in which y is in the range of from 1×10⁻⁴ to 0.2.
 6. An X-ray intensifying screen according to claim 4 in which M includes lithium ions.
 7. An X-ray intensifying screen according to claim 6 in which M is lithium and y is in the range of from 8×10⁻⁴ to 0.15.
 8. An X-ray intensifying screen according to claim 7 in which z is in the range of from 1×10⁻³ to 0.2.
 9. An X-ray intensifying screen according to claim 4 in which M includes at least one of sodium and potassium ions.
 10. An X-ray intensifying screen according to claim 9 in which M represents at least one of sodium and potassium and y is in the range of from 8×10⁻⁴ to 7×10⁻².
 11. An X-ray intensifying screen according to claim 10 in whichz is in the range of from 1×10⁻³ to 0.2.
 12. An X-ray intensifying screen according to claim 4 in which M includes at least one of cesium and rubidium ions.
 13. An X-ray intensifying screen according to claim 4 in which M includes at least two alkali metal activators chosen from among lithium, sodium, and potassium.
 14. An X-ray intensifying screen according to claim 13 in which M includes lithium and potassium ions.
 15. An X-ray intensifying screen comprised ofa support and a fluorescent layer containing an organic binder that is transparent to X-radiation and to radiation emitted when the layer is excited by X-radiation and a phosphor capable of absorbing X-radiation and emitting longer wavelength electromagnetic radiation comprised of monoclinic crystals of a hafnium dioxide phosphor consisting essentially of oxygen and combined elements satisfying the relationship

    Hf.sub.1-z Zr.sub.z Ti.sub.x

whereinx is in the range of from 3×10⁻⁴ to 1.0 and z is in the range of from 4×10⁻⁴ to 0.3, said phosphor exhibiting a higher luminescence intensity when excited by X-radiation as compared to the phosphor as described above absent titanium.
 16. An X-ray intensifying screen according to claim 15 in which x is in the range of from 3×10⁻⁴ to 0.5.
 17. An X-ray intensifying screen according to claim 16 in which x is in the range of from 3×10⁻⁴ to 0.25.
 18. An X-ray intensifying screen according to claim 17 in which z is in the range of from 1×10⁻³ to 0.2.
 19. An X-ray intensifying screen comprised ofa support and a fluorescent layer containing an organic binder that is transparent to X-radiation and to radiation emitted when the layer is excited by X-radiation and a phosphor capable of absorbing X-radiation and emitting longer wavelength electromagnetic radiation comprised of monoclinic crystals of a hafnium dioxide phosphor consisting essentially of oxygen and combined elements satisfying the relationship

    Hf.sub.1-z Zr.sub.z L.sub.w

whereinL represents at least one rare earth element selected from the group consisting of praseodymium, samarium, europium, gadolinium, terbium, dysprosium, and ytterbium; w is in the range of from 3×10⁻⁴ to <5×10⁻² ; and z is in the range of from 4×10⁻⁴ to 0.3, said phosphor exhibiting a higher luminescence intensity when excited by X-radiation as compared to the phosphor as described above absent L.
 20. An X-ray intensifying screen comprised ofa support and a fluorescent layer containing an organic binder that is transparent to X-radiation and to radiation emitted when the layer is excited by X-radiation and a phosphor capable of absorbing X-radiation and emitting longer wavelength electromagnetic radiation comprised of monoclinic crystals of a hafnium dioxide phosphor consisting essentially of oxygen and combined elements satisfying the relationship

    Hf.sub.1-z Zr.sub.z M.sub.y Ti.sub.x

whereinM represents at least one alkali metal; x is in the range of from 3×10⁻⁴ to 1.0; y is in the range of from 6×10⁻⁴ to 1.0; and z is in the range of from 4×10⁻⁴ to 0.3.
 21. An X-ray intensifying screen according to claim 20 in whichx is in the range of from 3×10⁻⁴ to 0.5; y is in the range of from 8×10⁻⁴ to 0.2; and z is in the range of from 1×10⁻³ to 0.2. 